International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 2 Issue 10, October - 2013

Reverse Engineering using CMM and CAD Tool

Dr. S.B. Thakare
Professor,
Deptt.of Mechanical Engg.
PRMIT & R, Badnera

Mr. Aniket Awate

Final Year Bachelor of Engineering Student
Deptt.of Mechanical Engg.
PRMIT & R, Badnera

Abstract

1. Introduction

Reverse engineering is a process by which the design of

a product is analyzed or recreated using a physical part
as a starting point. During the design process for a new
product, clay models and different types of prototypes
are made in order to test, evaluate and validate the
conceptual design. This process is usually iterative and
requires several modifications to the original design. For
that reason, reverse engineering can become a valuable
solution for extracting the dimensions of handmade
models, clay models and prototypes; especially those
with freeform shapes. You could also acquire the 3D
geometry of an existing object in order to incorporate
some of its features in the new product design. In
addition to that, 3D scanning solutions also provide a
powerful tool for documenting and archiving the
different design iterations.The critical steps in reverse
engineering are acquiring, accurately and efficiently, the

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dimensions of the object and extracting the

necessaryinformation from the resulting scan in order to
create the new design with the right look and
functionality.
Reverse engineering is alsodefined as the process of
obtaining a geometric CADmodel from 3D points
acquired by scanning/ digitizingthe existing products.[1]
Reverse Engineeringoriginally emerged as the answer to
provide spares forreplacing broken or worn out parts for
which notechnical data was available. This can be the
case if thepart was originally imported (without
drawings) or thedrawings being misplaced or lost.
Reverse Engineering has been defined as a process
forobtaining the technical data of a critical
sparecomponent.Computer-aidedreverse
engineering
relieson the use of computer-aided tools for obtaining
thepart geometry, identifying its material, improving
thedesign, tooling fabrication, manufacturing planning
andphysical realization. A solid model of the part is
thebackbone for computer-aided reverse engineering.
Themodel data can be exported from or imported
intoCAD/CAE/CAM systems using standard formats
suchas IGES, STL, VDA and STEP. [2]
The data-collecting unit in a CMM is theprobe.
Therefore, selection of probe and its positioningis very
crucial. Instructions must be given to CMMsystem for
the speed for positioning the probe, the pathto be
followed by the probe, angle at which the
probeapproaches etc. Then, the data about the checked
part issent back to the computer, where the original
partgeometry is stored. The part geometry as designed
iscompared with the part produced and the
resultantdeviation could be identified. It helps in
identifyingproblems in manufacturing. [3]

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In this paper, approach for Reverse Engineering (RE)

technique using Coordinate Measuring Machine
(CMM) and a design software CATIA ispresented.A part
is physically examined with the help of
CoordinateMeasuring Machine (CMM). Point cloud
data of a part is generated through scanning on CMM.
Point cloud data is then exported to CAD software
CATIA to generate CAD model of a part. Thus, this
report describes the processes of RE, from object
digitizationto CAD model reconstruction and error
analysis.
A case study of RE using CMM and CAD tool is
presented considering a part i.e. cover plate of gear box
of JADHAO Rotavator is presented and finally
important conclusions are drawn.

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International Journal of Engineering Research & Technology (IJERT)

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ISSN: 2278-0181
Vol. 2 Issue 10, October - 2013

Figure 1.Interrelation among CNC machine tool, CAD system and a CMM
Following are some of the reasons for using reverse
engineering:
* The original manufacturer no longer exists, but a
customer needs the product, e.g., aircraft spares required
typically after an aircraft has been in service for several
years.
* The original manufacturer of a product no longer
produces the product, e.g., the original product has
become
obsolete.
* The original product design documentation has been
lost
or
never
existed.
* Creating data to refurbish or manufacture a part for
which there are no CAD data, or for which the data have
become
obsolete
or
lost.
* Inspection and/or Quality ControlComparing a
fabricated part to its CAD description or to a standard
item.
* Some bad features of a product need to be eliminated
e.g., excessive wear might indicate where a product
should
be
improved.
* Analyzing the good and bad features of competitors
products.
* Exploring new avenues to improve product
performance
and
features.
* Creating 3-D data from a model or sculpture for
animation
in
games
and
movies.

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* Creating 3-D data from an individual, model or

sculpture to create, scale, or reproduce artwork.
The RE process can be divided into three steps:
Digitizing;
Data segmentation;
Data fitting
The first objective of RE methodology is togenerate a
conceptual model (example: surfacetriangulated) from a
physical model: a sample (partor tool) or prototype. In
this sense the 3D-scanning(digitising) techniques aided
by specialized softwares for model reconstruction are
necessary.3D-scanning (digitizing) is the process
ofgathering
data
from
an
undefined
threedimensionalsurface.
During
the
scanning
process,an analogue-scanning probe is commanded to
moveback and forth (contact or non-contact) across
theunknown surface. During this process, the
systemrecords information about the surface in the form
ofnumerical datagenerates a points cloud matrix(3Dcoordinates). [5]
2. Methodology
In this project work reverse engineeringapproach is
utilized for preparation of CAD model.In thiswork

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International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 2 Issue 10, October - 2013

CMM named Global Classis CMM HexagonClassic SR

is used for the collection of point cloud data. It is
collected by mechanical method i.e.using touch probe.
The CMM probe collects databy touching the surface
along the completeprofile of the part. It gives data in the
form ofpoint cloud which is then exported to any
CADmodeling software for converting it into CAD
model.In this case CATIA software is used
forconverting the point cloud data into CAD model.
Inthis software first all points are joined. They are
padded to form the 3D model of the coverplate.This
CAD model can also be used forthepreparation of
inspection program.

Figure 3 Point cloud data obtained from

CMM
All the points in the point cloud dataare joined for the
preparation of CAD model.Figure 4.shows the model
when all the points arejoined.

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3. Point Cloud Generation using CMM

A coordinate measuring machineis adevice for
measuring the physical geometricalcharacteristics of an
object. This machine may bemanually controlled by an
operator or it may bedirect computer controlled (DCC).
In this work, a coverplate of gear box is studied. Any
details except itsphysical model were not available. The
main task aheadwas to prepare its physical model. The
cover plateis shown in Figure 2.

the component. This point cloud datawas then imported

to the modeling softwareCATIA. Figure 3 shows the
point clouddata as seen in CATIA.

Figure 2 Cover plate of gear box

The job of obtaining CAD model fromphysical model
consists of following steps:
i. Scanning the physical part with the help ofCMM.
ii. To obtain point cloud data of a component
through CMM scanning.
iii. To export this cloud point data of CMM(PCDMIS
software) to the modelingsoftware (preparation of
IGES, STET,STL file).
iv. To prepare a CAD model & obtain thevarious
dimensions of the component.
v. Importing the CAD model to the PCDMISsoftware&
preparing inspection programfor error analysis.
In this study, first the scanning of physicalmodel of
cover plate was done. It gives the pointcloud data for

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Figure 4 Point cloud data when all the points

arejoined in CATIA
ACAD model is prepared fromthe point cloud data
using various commands in theCATIA software. Figure
5 shows the CAD modelof the cover plate.

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International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 2 Issue 10, October - 2013

Reference
1] Niranjan Singh, Reverse Engineering- AGeneral
Review, International Journal ofAdvanced Engineering
Research and Studies,Vol. II/ Issue I/Oct.-Dec.,
2012.pp.24-28.
[2] D. K. Pal, Dr. B. Ravi, L. S. Bhargava,
U.Chandrasekhar, Computer-Aided ReverseEngineering
for Rapid Replacement Parts: ACase Study, Defence
Science Journal,DESSIDOC, DRDO, New Delhi, 2005.
[3] www.ignou.ac.in/upload/Unit-8-62.pdf
[4] Colin Bradley, Bernadette Currie, Advances inthe

Figure 5 CAD model of Cover Plate of Gear Box

Field of Reverse Engineering, Computer-Aided Design

& Applications, Vol. 2, No. 5,2005, pp 697-706.
[5] M. Sokovic, J. Kopac, RE (reverseengineering) as
necessary phase by rapidproduct development, Journal

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All the dimensions of the parts which arenot known can

be easily found with the help ofabove CAD model.In
the next stage, this CAD model wasimported to the
PCDMIS software where it wasused for preparation of
inspection program. Alsowith the help of this inspection
program all thecomponents that are manufactured in
future can beinspected for error analysis.

of

MaterialsProcessing

Technology

175

(2006),

pp.398403.

Conclusion
The above study shows that usingCoordinate Measuring
Machine helps to get theunknown details of any
component. The intricatedimensions which are not
possible to measure byany other method can be
measured easily. Thedesign process can also be
simplified and costincurred in designing is also
minimum. Also theinspection activity is simplified with
the help ofCMM machine.

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